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Yamaha MIO Service Manual

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SERVICE MANUAL
5TL-F8197-E0

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  • Page 1 SERVICE MANUAL 5TL-F8197-E0...
  • Page 3 EAS00000 AL115 SERVICE MANUAL ©2003 by Yamaha Motor Co., Ltd. First edition, July 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of motorcycle.
  • Page 5 EASF0001 HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is a chapter with its symbol on the upper right of each page. 2nd title 2: This title appears on the upper of each page on the left of the chapter symbol.

  • Page 6: General Information

    EASF0002 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor 6 Chassis 7 Electrical system CHAS CARB 8 Troubleshooting...

  • Page 7: Table Of Contents

    EASF0003 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR CARB CHASSIS CHAS – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 9 INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION..............1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 ENGINE SERIAL NUMBER ..............1-1 IMPORTANT INFORMATION ................. 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-2 REPLACEMENT PARTS................1-2 GASKETS, OIL SEALS AND O-RINGS ............ 1-2 LOCK WASHERS/PLATES AND COTTER PINS ........1-3 BEARINGS AND OIL SEALS ..............
  • Page 10 INFO...

  • Page 11: General Information

    MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase. NOTE: Designs and specifications are subject to change without notice.

  • Page 12: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 13: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...

  • Page 14: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 15: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 16 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Tappet adjusting tool 90890-01311 This tool is necessary for adjusting valve clearance. Fuel level gauge 90890-01312 This gauge is used to measure the fuel level in the float chamber. T-handle 90890-01326 This tool is used for holding the damper rod holder when removing or installing the damper rod holder.
  • Page 17 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Compression gauge 90890-03081 These tools are used to measure the engine compression. Pocket tester 90890-03112 These instruments are invaluable for checking the electrical system. Engine tachometer 90890-03113 This tool is needed for detecting engine rpm.
  • Page 18 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Yamaha bond No. 1215 90890-85505 This sealant (bond) is used for crank- case mating surface, etc. 1 - 8...
  • Page 19 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-9 ELECTRICAL SPECIFICATIONS ..............2-12 CONVERSION TABLE .................. 2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-15 TIGHTENING TORQUES ................2-16 ENGINE TIGHTENING TORQUES............2-16 CHASSIS TIGHTENING TORQUES............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-20 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ....
  • Page 20 SPEC...

  • Page 21: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model AL115 Model code 5LT1 Dimensions Overall length 1,820 mm (71.7 in) Overall width 675 mm (26.6 in) Overall height 1,050 mm (41.3 in) Seat height 745 mm (29.3 in) Wheelbase 1,240 mm (48.8 in) Minimum ground clearance 130 mm (5.12 in) Minimum turning radius...

  • Page 22: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Forced-air-cooled 4-stroke, SOHC ---- Displacement 113.7 cm (6.94 cu.in) ---- Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 50.0 × 57.9 mm (1.97 × 2.28 in) ---- Compression ratio 8.8:1 ---- Standard compression pressure...
  • Page 23 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshaft Drive system Chain drive (left) ---- Intake camshaft lobe dimensions Measurement A 25.881 ~ 25.981 mm (1.0189 ~ 1.0229 in) 25.780 mm (1.0150 in) Measurement B 21.195 ~ 21.295 mm (0.8344 ~ 0.8384 in) 21.095 mm (0.8305 in) Exhaust camshaft lobe dimensions Measurement A...
  • Page 24 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve, valve seat, valve guide Valve clearance (cold) 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) ---- 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) ---- Valve dimensions Head Diameter Face Width Seat Width Margin Thickness “A”...
  • Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake 35.44 mm (1.40 in) 34.00 mm (1.34 in) Exhaust 35.44 mm (1.40 in) 34.00 mm (1.34 in) Installed length (valve closed) Intake 24.1 mm (0.95 in) ---- Exhaust 24.1 mm (0.95 in) ---- Compressed spring force (installed) Intake...
  • Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston Piston-to-cylinder clearance 0.020 ~ 0.035 mm (0.0008 ~ 0.0014 in) 0.150 mm (0.0059 in) Diameter D 49.970 ~ 49.985 mm (1.9673 ~ 1.9679 in) ---- Height H 5 mm (0.20 in) ---- Piston pin bore (in the piston) Diameter 15.002 ~ 15.013 mm (0.5906 ~ 0.5911 in) 15.043 mm (0.5922 in)
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil ring Dimensions (B × T) 2.00 × 2.25 mm (0.079 × 0.089 in) ---- End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ---- Crankshaft Crank width “A” 45.45 ~ 45.50 mm (1.789 ~ 1.791 in) ---- Max.
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Kickstarter Kickstarter type Ratchet type ---- Kickstarter pinion gear clip friction 1.0 ~ 3.5 N (0.10 ~ 0.36 kgf, 0.22 ~ 0.79 lb) ---- force Air filter Air filter element Dry element ---- Carburetor Type (manufacturer)/quantity NCV24 (KEIHIN)/1 ----...

  • Page 29: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Steel tube underbone ---- Caster angle 26.5° ---- Trail 100 mm (3.94 in) ---- Front wheel Wheel type Spoke wheel ---- 14 × 1.40 Size ---- Material Steel ---- Wheel travel 90 mm (3.54 in) ----...
  • Page 30 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type With tube ---- Size 80/90-14M/C 40P ---- Manufacturer/model IRC/NR76 ---- Tire pressure (cold tire) 0 ~ 90 kg 225 kPa (2.25 kgf/cm , 33 psi) ---- Min. tire tread depth ---- 0.8 mm (0.031 in)
  • Page 31 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 90 mm (3.54 in) ---- Spring Free length 266.7 mm (10.50 in) 261.4 mm (10.29 in) Installed length 256.7 mm (10.11 in) ---- Spring rate (K1)

  • Page 32: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type C.D.I. ---- Ignition timing (B.T.D.C.) 5° at 1,500 r/min ---- Advanced type Electrical (Analogue) ---- DC.C.D.I. Magneto model/manufacturer F5TL/PT. MORIC ---- 248 ~ 372 Ω at 20 °C (68 °F)/W/L–W/R Pickup coil resistance/color ---- C.D.I.
  • Page 33 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Bulbs (voltage/wattage × quantity) 12 V 32 W/32 W × 1 Headlight ---- 12 V 5 W/21 W × 1 Tail/brake light ---- 12 V 10 W × 2 Front turn signal light ---- 12 V 10 W ×...
  • Page 34 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage × quantity) 10 A × 1 Fuse ---- 10 A × 1 Reserve fuse ---- 2 - 14...

  • Page 35: Conversion Table

    CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.

  • Page 36: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Spark plug — Cylinder head Cylinder head (timing chain side) Bolt Cylinder head stud bolt Bolt Oil gallery bolt Bolt...
  • Page 37 SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Primary sheave nut Idle gear plate Bolt Starter wheel gear holder Bolt Crankcase (left and right) Bolt Crankcase stud bolt Bolt Stator coil assembly Bolt...

  • Page 38: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Brake master cylinder Rear brake lever assembly Front brake lever Starter lever Handlebar nut Steering ring nut (upper) See NOTE Steering ring nut (lower) See NOTE...
  • Page 39 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Seat lock assembly and frame Rear fender Rectifier/regulator Footboard and frame Leg shield and frame License plate bracket and license plate stay License plate stay and frame Horn bracket and license plate stay Main switch and frame...

  • Page 40: Lubrication Points And Lubricant Types

    Secondary sheave guide pin ® Grease R Shell Dolium Secondary fixed sheave inner surface ® Grease R Shell Dolium Secondary sliding surface ® Grease R Idle gear shaft Centerstand pivot Sidestand pivot Crankcase mating surfaces Yamaha bond No.1215 2 - 20...

  • Page 41: Chassis Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Front wheel oil seal lips Front wheel axle Speedometer gear unit inner surface and oil seal lip Brake caliper bolt (upper and lower) and boot Brake cam pivot shaft and camshaft surface Brake lever pivot shaft Tube guide (throttle grip) inner surface...

  • Page 42: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Front brake light switch lead 0 Throttle cable 2 Right handlebar switch lead 3 Rear brake cable È Connect the meter assembly coupler on the left 4 Left handlebar switch lead side of the meter assembly. 5 Rear brake light switch leads É...
  • Page 43 SPEC CABLE ROUTING Ë Pass the wire harness and speedometer cable through the guide, and then install the grommet on the front brake hose in the holder. Ì Route the front brake light switch lead behind the front brake hose, and then connect it on the right side of the meter assembly.
  • Page 44 SPEC CABLE ROUTING 1 Wire harness B Horn leads 2 Speedometer cable 3 Front brake hose È Pass the speedometer cable through the cable 4 Starter cable guide as shown. 5 Rear brake cable É Fasten the starter cable, rear brake cable, and 6 Throttle cable throttle cable with the holder.
  • Page 45 SPEC CABLE ROUTING Ì Pass the starter motor lead through the hole in the storage box. Í Fasten the main switch lead, starter cable, rear brake cable, and throttle cable with the holder. Î To the turn signal lights Î Í...
  • Page 46 SPEC CABLE ROUTING 1 Starter cable È Pass the fuel hose and vacuum hose through 2 Throttle cable the hole in the rear fender. 3 Fuel hose É Route the fuel overflow hose as shown 4 Vacuum hose Ê Pass the fuel overflow hose through the hole in 5 Starter motor lead the bottom cowling 6 Fuel overflow hose...
  • Page 47 SPEC CABLE ROUTING 1 Positive battery lead B Front turn signal light lead (left) 2 Starter relay lead C Front turn signal light lead (right) 3 Fuse lead 4 Battery breather hose 2 È Install the battery breather 1 hose to the battery. 5 Wire harness É...
  • Page 48 SPEC CABLE ROUTING Ì Fasten the wire harness with the holders. Ò Route the front turn signal light lead (left) Í Fasten the grommet on the wire harness with between the front turn signal light (left) and the the holder as shown. screw support on the front cowling as shown.
  • Page 49 SPEC CABLE ROUTING 1 Tail/brake light assembly B C.D.I. unit 2 Tail/brake light assembly coupler C Positive battery lead 3 Fuel sender lead D Starter relay lead 4 A.C. magneto lead couplers E Fuse lead 5 Spark plug lead F Fuse 6 Ignition coil G Starter relay 7 Negative battery lead...
  • Page 50 SPEC CABLE ROUTING Ê Fasten the tail/brake light lead and rear turn sig- nal light lead (left) with the holder. Ë Fasten the fuse lead, starter relay lead, and pos- itive battery lead with the holder. Ì To the starter motor Í...
  • Page 51 SPEC CABLE ROUTING 1 Wire harness B Throttle cable 2 Spark plug lead C Starter cable 3 Ignition coil D Rear brake cable 4 Ignition coil lead E Spark plug lead 5 A.C. magneto lead 6 Negative battery lead 7 Starter motor 8 Starter motor lead 9 Vacuum hose 0 Fuel hose...
  • Page 52 SPEC CABLE ROUTING È Fasten the wire harness with the holders. Í Fasten the throttle cable at the white mark and É Route the cylinder head breather hose as the starter cable grommet with the holder. Î Install the spark plug cap securely so that there shown.
  • Page 53 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ......3-1 COVERS ......................3-3 REMOVING THE SEAT AND SIDE COVERS .......... 3-3 INSTALLING THE SEAT AND SIDE COVERS......... 3-3 REMOVING THE FRONT COWLING AND LEG SHIELD ......3-4 INSTALLING THE FRONT COWLING AND LEG SHIELD .......3-6 REMOVING THE HEADLIGHT ASSEMBLY..........3-7 INSTALLING THE HEADLIGHT ASSEMBLY ...........3-7...
  • Page 54 ELECTRICAL SYSTEM................. 3-37 CHECKING AND CHARGING THE BATTERY........3-37 CHECKING THE FUSE................3-41 REPLACING THE HEADLIGHT BULB............3-42 ADJUSTING THE HEADLIGHT BEAM ...........3-43...

  • Page 55: Periodic Checks And Adjustments

    INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION CHART EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 56 23 * switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice. NOTE: From 16,000 km (10,000 mi), repeat the maintenance intervals starting from 4,000 km (2,500 mi).

  • Page 57: Covers

    COVERS EASF0004 COVERS REMOVING THE SEAT AND SIDE COVERS 1. Remove: • seat 1 2. Remove: • center cover 1 3. Remove: • rear panel 1 NOTE: Remove the rear panel by sliding it up in the direction of the arrow shown. 4.

  • Page 58: Removing The Front Cowling And Leg Shield

    COVERS 2. Install: • rear panel 1 NOTE: Make sure that all projections are securely fit- ted. 3. Install: • seat 1 7 Nm (0.7 m · kg, 5.1 ft · lb) REMOVING THE FRONT COWLING AND LEG SHIELD 1. Remove: •...
  • Page 59 COVERS 3. Remove: • bottom cowling 1 4. Remove: • front bottom cowling 1 5. Remove: • battery breather hose 2 1 footboard • 6. Remove: • main switch cover 1 • leg shield 2 NOTE: Remove the main switch cover by turning it in the direction of the arrow shown.

  • Page 60: Installing The Front Cowling And Leg Shield

    COVERS INSTALLING THE FRONT COWLING AND LEG SHIELD For installation, reverse the removal proce- dure. 1. Install: • footboard 1 • battery breather hose 2 2 Refer to “CABLE ROUTING” in chapter 2. 2. Install: • front bottom cowling 1 3.

  • Page 61: Removing The Headlight Assembly

    COVERS REMOVING THE HEADLIGHT ASSEMBLY 1. Remove: • headlight assembly 1 2. Disconnect: • headlight connectors 1 INSTALLING THE HEADLIGHT ASSEMBLY For installation, reverse the removal proce- dure. 3 - 7...

  • Page 62: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at the Top Dead Center (TDC) on the compression stroke.
  • Page 63 ADJUSTING THE VALVE CLEARANCE 4. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) Exhaust valve 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) M MMM M MMM M MMM M MMM M MMM...

  • Page 64: Adjusting The Engine Idling Speed

    ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. Locknut 7 Nm (0.7 m · kg, 5.1 ft · lb) e. Measure the valve clearance again. f.
  • Page 65 ADJUSTING THE ENGINE IDLING SPEED 2. Remove: • seat • center cover Refer to “REMOVING THE SEAT AND SIDE COVERS”. 3. Connect: • engine tachometer (onto the spark plug lead) Engine tachometer 90890-03113 4. Check: • engine idling speed Out of specification → Adjust. Engine idling speed (with head- light on) 1,400 ~ 1,600 r/min...

  • Page 66: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 7. Install: • center cover • seat Refer to “INSTALLING THE SEAT AND SIDE COVERS”. EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted.

  • Page 67: Checking The Spark Plug

    CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1. Remove: • seat • center cover Refer to “REMOVING THE SEAT AND SIDE COVERS”. 2. Disconnect: • spark plug cap 3. Remove: • spark plug CAUTION: Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from fall- ing into the cylinder.

  • Page 68: Measuring The Compression Pressure

    CHECKING THE SPARK PLUG/ MEASURING THE COMPRESSION PRESSURE 10.Install: • center cover • seat Refer to “INSTALLING THE SEAT AND SIDE COVERS”. EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: •...
  • Page 69 MEASURING THE COMPRESSION PRESSURE 6. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 960 kPa (9.6 kg/cm , 136.5 psi) Standard 1,100 kPa (11 kg/cm , 156.5 psi) Maximum 1,230 kPa (12.3 kg/cm...

  • Page 70: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 8. Connect: • spark plug cap 9. Install: • footboard • front bottom cowling • bottom cowling • front cowling Refer “INSTALLING FRONT COWLING AND LEG SHIELD”. EAS00070 CHECKING THE ENGINE OIL LEVEL 1.

  • Page 71: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 6. Start the engine, warm it up for several min- utes, and then turn it off. 7. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.

  • Page 72: Changing The Transmission Oil

    CHANGING THE ENGINE OIL/ CHANGING THE TRANSMISSION OIL 8. Fill: • crankcase (with the specified amount of the recom- mended engine oil) Quantity Total amount 0.9 L (0.79 Imp qt, 0.95 US qt) Periodic replacement 0.8 L (0.70 Imp qt, 0.85 US qt) 9.

  • Page 73: Cleaning The Air Filter Element

    CHANGING THE TRANSMISSION OIL/ CLEANING THE AIR FILTER ELEMENT 7. Fill: • transmission case (with the specified amount of the recom- mended transmission oil) Recommended oil Engine oil Quantity Total amount 0.12 L (0.11 Imp qt, 0.13 US qt) Periodic replacement 0.10 L (0.09 Imp qt, 0.11 US qt) 8.

  • Page 74: Checking The V-Belt

    CLEANING THE AIR FILTER ELEMENT/ CHECKING THE V-BELT 4. Install: • air filter element • air filter case cover CAUTION: Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.

  • Page 75: Cleaning The V-Belt Case Air Filter Element

    CLEANING THE V-BELT CASE AIR FILTER ELEMENT EAS00091 CLEANING THE V-BELT CASE AIR FILTER ELEMENT NOTE: On the bottom of the V-belt case cover is a check hose 1. If dust or water or both collects in this hose, clean the V-belt air filter elements. 1.

  • Page 76: Checking The Carburetor Joint And Intake Manifold

    CLEANING THE V-BELT CASE AIR FILTER ELEMENT/ CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD CAUTION: Do not twist or wring out the element. This could damage the foam material. c. Apply oil of the recommended type to the entire surface of the element, and then squeeze the excess oil out.

  • Page 77: Checking The Fuel And Vacuum Hoses

    CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/ CHECKING THE FUEL AND VACUUM HOSES/ CHECKING THE BREATHER HOSES 3. Install: • left side cover • rear panel • center cover • seat Refer to “INSTALLING THE SEAT AND SIDE COVERS”. EAS00096 CHECKING THE FUEL AND VACUUM HOSES 1.

  • Page 78: Checking The Breather Hoses

    CHECKING THE BREATHER HOSES/ CHECKING THE EXHAUST SYSTEM 2. Check: • cylinder head breather hose 1 • crankcase breather hose 2 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: Make sure the cylinder head breather hose is routed correctly. 3.

  • Page 79: Chassis

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL EAS00108 CHASSIS EAS00114 ADJUSTING THE REAR BRAKE 1. Check: • brake lever free play a Out of specification → Adjust. Brake lever free play (lever end) 10 ~ 20 mm (0.39 ~ 0.79 in) 2.

  • Page 80: Checking The Front Brake Pads

    CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT BRAKE PADS WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.

  • Page 81: Checking The Rear Brake Shoes

    CHECKING THE REAR BRAKE SHOES/CHECKING THE FRONT BRAKE HOSE/BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00126 CHECKING THE REAR BRAKE SHOES 1. Operate the brake. 2. Check: • wear indicator 1 Reaches the wear limit line 2 → Replace the brake shoes as a set. Refer to “REAR WHEEL AND BRAKE”...

  • Page 82: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM NOTE: • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to over- flow. • When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably length- ening the bleeding procedure.

  • Page 83: Checking And Adjusting The Steering Head

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHECKING AND ADJUSTING THE STEERING HEAD WARNING After bleeding the hydraulic brake system, check the brake operation. L LLL L LLL L LLL L LLL L LLL EAS00148 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
  • Page 84 CHECKING AND ADJUSTING THE STEERING HEAD 4. Adjust: • steering head M MMM M MMM M MMM M MMM M MMM a. Loosen the upper ring nut 1. b. Loosen the lower ring nut 2 and then tighten it to specification with the steering nut wrench 3.

  • Page 85: Checking The Front Fork

    CHECKING THE FRONT FORK/ CHECKING THE TIRES EAS00149 CHECKING THE FRONT FORK 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Check: • inner tube Damage/scratches →...
  • Page 86 CHECKING THE TIRES WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
  • Page 87 Tube or tubeless Tubeless wheel tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.

  • Page 88: Checking The Wheels

    CHECKING THE WHEELS/ CHECKING AND TIGHTENING THE SPOKES EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: • wheel Damage/out-of-round → Replace. WARNING Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel.

  • Page 89: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS/ LUBRICATING THE SIDESTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible.

  • Page 90: Lubricating The Centerstand

    LUBRICATING THE CENTERSTAND EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Recommended lubricant Lithium-soap-based grease 3 - 36...

  • Page 91: Chk Adj

    CHECKING AND CHARGING THE BATTERY EAS00176 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 92 CHECKING AND CHARGING THE BATTERY 4. Disconnect: • battery leads (from the battery terminals) CAUTION: First, disconnect the negative battery lead 1, and then positive battery lead 2. 5. Remove: • battery 3 6. Disconnect: • battery breather hose 1 4 •...
  • Page 93 CHECKING AND CHARGING THE BATTERY 9. Charge: • battery Battery charging amperage and time 0.5 amps/10 hrs WARNING Do not quick charge a battery. CAUTION: • Loosen the battery sealing caps. • Make sure the battery breather hose and battery vent are free of obstructions. •...
  • Page 94 CHECKING AND CHARGING THE BATTERY NOTE: Replace the battery whenever: • battery voltage does not rise to specification or bubbles fail to rise during charging, • sulphation of one or more battery cells occurs (as indicated by the battery plates turning white or material accumulating in the bottom of the battery cell), •...

  • Page 95: Checking The Fuse

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSE 15.Lubricate: • battery terminals Recommended lubricant Dielectric grease 16.Close the lid 1 and hook the battery band 17.Install: • right side cover • rear panel • center cover Refer to “INSTALLING THE SEAT AND SIDE COVERS”.

  • Page 96: Replacing The Headlight Bulb

    CHECKING THE FUSE/ REPLACING THE HEADLIGHT BULB 4. Replace: • blown fuse WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

  • Page 97: Adjusting The Headlight Beam

    REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 4. Install: • headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.

  • Page 99: Eng

    CHAPTER 4 ENGINE REMOVING THE ENGINE................4-1 ENGINE OIL ....................4-1 COVERS ....................4-1 CARBURETOR ..................4-1 MUFFLER....................4-2 CABLE AND HOSE ................... 4-2 REAR SHOCK ABSORBER ASSEMBLY BOLT ........4-3 ENGINE ASSEMBLY ................4-3 INSTALLING THE ENGINE................4-4 ENGINE ASSEMBLY ................4-4 REAR SHOCK ABSORBER ASSEMBLY BOLT ........
  • Page 100 CYLINDER AND PISTON................4-32 REMOVING THE CYLINDER AND PISTON...........4-33 CHECKING THE CYLINDER AND PISTON ...........4-34 CHECKING THE PISTON RINGS............4-35 CHECKING THE PISTON PIN ..............4-36 INSTALLING THE PISTON AND CYLINDER .........4-37 KICKSTARTER ..................... 4-39 REMOVING THE KICKSTARTER............4-40 DISASSEMBLING THE KICKSTARTER SHAFT ........4-40 CHECKING THE KICKSTARTER ............
  • Page 101 CRANKSHAFT ....................4-73 DISASSEMBLING THE CRANKCASE............4-74 REMOVING THE CRANKSHAFT ASSEMBLY ........4-75 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE..... 4-76 CHECKING THE CRANKSHAFT AND CONNECTING ROD ....4-76 CHECKING THE CRANKCASE ..............4-77 CHECKING THE BEARINGS AND OIL SEALS........4-77 INSTALLING THE CRANKSHAFT ............4-78 ASSEMBLING THE CRANKCASE............

  • Page 103: Removing The Engine

    REMOVING THE ENGINE EASF0018 ENGINE REMOVING THE ENGINE NOTE: It is not necessary to remove the engine in order to remove the following components. • Cylinder head • Cylinder • Piston • Starter clutch • Starter motor • Kickstarter shaft •...

  • Page 104: Muffler

    REMOVING THE ENGINE MUFFLER 1. Remove: • muffler nuts 1 2. Remove: • muffler bolts 1 • washer • nuts • washer • spacer • damper • muffler 2 • muffler stay bolts 3 • washers • muffler stay 4 CABLE AND HOSE 1.

  • Page 105: Rear Shock Absorber Assembly Bolt

    REMOVING THE ENGINE REAR SHOCK ABSORBER ASSEMBLY BOLT 1. Remove: • rear shock absorber assembly bolt 1 ENGINE ASSEMBLY 1. Remove: • engine mounting nut 1 • washer • engine mounting bolt 2 • engine assembly WARNING Securely support the motorcycle so there is no danger of it falling over.

  • Page 106: Installing The Engine

    INSTALLING THE ENGINE EASF0019 INSTALLING THE ENGINE ENGINE ASSEMBLY WARNING Securely support the motorcycle so there is no danger of it falling over when install- ing engine. 1. Install: • engine assembly • engine mounting bolt • washer • engine mounting nut 59 Nm (5.9 m ·...

  • Page 107: Muffler

    INSTALLING THE ENGINE MUFFLER 1. Install: • muffler stay 1 (to the muffler 2) • muffler upper bolt 3 (install without tightening) • nut 4 • damper 5 • spacer 6 • washer 7 • muffler lower bolt 8 (install without tightening) •...

  • Page 108: Carburetor

    INSTALLING THE ENGINE CARBURETOR 1. Install: • carburetor assembly Refer to “CARBURETOR” in chapter 5. • air filter case Refer to “AIR FILTER CASE” in chapter 5. • fuel tank Refer to “FUEL TANK” in chapter 5. 2. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...

  • Page 109: Cylinder Head

    CYLINDER HEAD EASF0023 CYLINDER HEAD 1 Cylinder head 8 O-ring F Rubber cover 2 Spark plug 9 Camshaft sprocket cover G Timing chain tensioner 3 O-ring 0 Dowel pin H Gasket 4 Tappet cover A Gasket I Ignition coil assembly bracket 5 Camshaft sprocket B Gasket J Ignition coil assembly...

  • Page 110: Removing The Cylinder Head

    CYLINDER HEAD EAS00225 REMOVING THE CYLINDER HEAD 1. Remove: • footboard Refer to “REMOVING THE FRONT COWL- ING AND LEG SHIELD” in chapter 3. 2. Remove: • fuel tank Refer to “FUEL TANK” in chapter 5. • air filter case Refer to “AIR FILTER CASE”...
  • Page 111 CYLINDER HEAD 7. Remove: • rubber cover 1 • air shroud (left) 2 • engine cooling fan cover 3 • air shroud (right) 4 8. Remove: • engine cooling fan 1 9. Align: • “I” mark a on the A.C. magneto rotor (with the stationary pointer b on the crank- case) M MMM...
  • Page 112 CYLINDER HEAD 10.Loosen: • camshaft sprocket bolt 1 NOTE: While holding the A.C. magneto rotor with the rotor holding tool 2, loosen the camshaft sprocket bolt. Rotor holding tool 90890-01235 11.Remove: • timing chain tensioner 1 (along with the gasket) 12.Remove: •...

  • Page 113: Checking The Cylinder Head

    CYLINDER HEAD EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: •...

  • Page 114: Checking The Timing Chain Guide

    CYLINDER HEAD CHECKING THE TIMING CHAIN GUIDE 1. Check: • timing chain guide (exhaust side) Damage/wear → Replace. EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage → Replace. M MMM M MMM M MMM M MMM M MMM a.
  • Page 115 CYLINDER HEAD 3. Tighten: • cylinder head nuts 22 Nm (2.2 m · kg, 16 ft · lb) • cylinder head bolts 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Lubricate the cylinder head nuts with engine oil.
  • Page 116 CYLINDER HEAD 5. Install • timing chain tensioner M MMM M MMM M MMM M MMM M MMM a. Remove the plug cap. b. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise.
  • Page 117 CYLINDER HEAD 8. Check: • “I” mark a Align the “I” mark on the A.C. magneto rotor with the stationary pointer b on the crank- case. • “I” mark c Align the “I” mark on the camshaft sprocket with the stationary pointer d on the cylinder head.
  • Page 118 CYLINDER HEAD 14.Install: • intake manifold • cylinder head breather hose holder • intake manifold bolts 10 Nm (1.0 m · kg, 7.2 ft · lb) 15.Install: • ignition coil assembly • ignition coil assembly screws 7 Nm (0.7 m · kg, 5.1 ft · lb) 16.Install: •...

  • Page 119: Camshaft

    CAMSHAFT EASF0020 CAMSHAFT 1 Locknut 5 Rocker arm shaft (intake side) 2 Adjusting screw 6 Rocker arm shaft (exhaust side) 3 Rocker arm (intake side) 7 Camshaft 4 Rocker arm (exhaust side) 8 Camshaft retainer 4 - 17...

  • Page 120: Removing The Rocker Arms And Camshaft

    CAMSHAFT EASF0022 REMOVING THE ROCKER ARMS AND CAMSHAFT NOTE: Prior to remove the rocker arms and camshaft, remove the cylinder head. 1. Loosen: • locknuts 1 • adjusting screws 2 2. Remove: • camshaft retainer 1 3. Remove: • camshaft 1 NOTE: Screw 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft.

  • Page 121: Checking The Camshafts

    CAMSHAFT EAS00205 CHECKING THE CAMSHAFTS 1. Check: • camshaft lobes → Blue discoloration/pitting/scratches Replace the camshaft. 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimension limit Intake a 25.881 ~ 25.981 mm (1.0189 ~ 1.0229 in) <Limit>: 25.780 mm (1.0150 in) b 21.195 ~ 21.295 mm...

  • Page 122: Checking The Rocker Arms And Rocker Arm Shafts

    CAMSHAFT EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: • rocker arm Damage/wear → Replace. 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches →...

  • Page 123: Checking The Camshaft Sprocket

    CAMSHAFT EAS00207 CHECKING THE CAMSHAFT SPROCKET 1. Check: • camshaft sprocket More than 1/4 tooth wear a → Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket EAS00212 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER...
  • Page 124 CAMSHAFT 3. Lubricate: • rocker arm shafts Recommended lubricant Molybdenum disulfide oil 4. Install: • exhaust rocker arm • intake rocker arm • exhaust rocker arm shaft • intake rocker arm shaft 5. Install: • camshaft retainer 1 • camshaft retainer bolt 12 Nm (1.2 m ·...

  • Page 125: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EASF0024 VALVES AND VALVE SPRINGS 1 Valve cotter 2 Upper spring seat 3 Valve spring 4 Valve stem seal 5 Lower spring seat 6 Intake valve 7 Exhaust valve 4 - 23...

  • Page 126: Removing The Valves

    VALVES AND VALVE SPRINGS EASF0025 REMOVING THE VALVES NOTE: Prior to remove the valves, remove the cylin- der head, rocker arms, and camshaft. The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.

  • Page 127: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 3. Remove: • upper spring seat 1 • valve spring 2 • valve stem seal 3 • lower spring seat 4 • valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES...
  • Page 128 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. M MMM M MMM M MMM M MMM M MMM a.

  • Page 129: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the valve stem seal. Valve stem runout 0.01 mm (0.0004 in) EAS00240...
  • Page 130 VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. L LLL L LLL L LLL L LLL L LLL 4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

  • Page 131: Checking The Valve Springs

    VALVES AND VALVE SPRINGS h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat.

  • Page 132: Installing The Valves

    VALVES AND VALVE SPRINGS 3. Measure: • valve spring tilt a Out of specification → Replace the valve spring. Valve spring tilt limit Intake and exhaust valve spring 2.5°/1.5 mm (2.5°/0.06 in) EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components.
  • Page 133 VALVES AND VALVE SPRINGS 4. Install: • valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor Valve spring compressor 90890-01253 Valve spring compressor attach- ment 90890-01243 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.

  • Page 134: Cylinder And Piston

    CYLINDER AND PISTON EASF0027 CYLINDER AND PISTON 1 Cylinder 8 Piston pin 2 Cylinder gasket 9 Piston pin circlip 3 Dowel pin 4 Top ring 5 2nd ring 6 Oil ring 7 Piston 4 - 32...

  • Page 135: Removing The Cylinder And Piston

    CYLINDER AND PISTON EASF0028 REMOVING THE CYLINDER AND PISTON NOTE: Prior to remove the cylinder and piston, remove the cylinder head. 1. Remove: • cylinder 1 2. Remove: • dowel pins 1 • gasket 2 3. Remove: • piston pin clip 1 •...
  • Page 136 CYLINDER AND PISTON EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: • piston wall • cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: • piston-to-cylinder clearance M MMM M MMM M MMM...

  • Page 137: Checking The Piston Rings

    CYLINDER AND PISTON Piston-to-cylinder clearance 0.020 ~ 0.035 mm (0.0008 ~ 0.0014 in) <Limit>: 0.15 mm (0.0059 in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. L LLL L LLL L LLL L LLL...

  • Page 138: Checking The Piston Pin

    CYLINDER AND PISTON Piston ring end gap Top ring 0.10 ~ 0.25 mm (0.004 ~ 0.010 in) <Limit>: 0.5 mm (0.020 in) 2nd ring 0.10 ~ 0.25 mm (0.004 ~ 0.010 in) <Limit>: 0.6 mm (0.024 in) Oil ring 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) EAS00265 CHECKING THE PISTON PIN 1.

  • Page 139: Installing The Piston And Cylinder

    CYLINDER AND PISTON EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: • top ring 1 • 2nd ring 2 • oil ring expander 3 • lower oil ring rail 4 • upper oil ring rail 5 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.
  • Page 140 CYLINDER AND PISTON 3. Install: • gasket 1 • dowel pins 2 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: • piston ring end gaps 120˚ a Top ring b Upper oil ring rail c Expander end 120˚...

  • Page 141: Kickstarter

    KICKSTARTER EASF0033 KICKSTARTER 1 V-belt case air filter cover 7 V-belt case cover protector 2 D Washer 2 V-belt case air filter dust seal 8 V-belt case cover protector 1 E Kickstarter pinion gear 3 V-belt case air filter element 9 Dowel pin F Kickstarter pinion gear clip 4 V-belt case air filter element...

  • Page 142: Removing The Kickstarter

    KICKSTARTER REMOVING THE KICKSTARTER 1. Remove: • footboard Refer to “REMOVING THE FRONT COWL- ING AND LEG SHIELD” in chapter 3. • V-belt case air filter element Refer to “CLEANING THE V-BELT CASE AIR FILTER ELEMENT” in chapter 3. 2. Loosen: •...

  • Page 143: Checking The Kickstarter

    KICKSTARTER 2. Remove: • kickstarter pinion gear 1 • kickstarter pinion gear clip 2 NOTE: Turn the kickstarter crank attached to the kick- starter shaft in the direction of the arrow a and remove the kickstarter pinion gear and kick- starter pinion gear clip together.

  • Page 144: Assembling The Kickstarter

    KICKSTARTER EAS00340 ASSEMBLING THE KICKSTARTER 1. Install: • spacer • kickstarter spring • kickstarter shaft • washer • circlip • oil seal NOTE: • Hook the straight end of the kickstarter spring onto the notch 1 in the kickstarter shaft and hook the hooked end of the kick- starter spring onto the projection 2 as shown.
  • Page 145 KICKSTARTER 3. Install: • V-belt case cover protector 2 • V-belt case cover protector 2 bolts 10 Nm (1.0 m · kg, 7.2 ft · lb) • V-belt case cover protector 1 • V-belt case cover protector 1 screws 7 Nm (0.7 m · kg, 5.1 ft · lb) •...

  • Page 146: Belt Drive

    BELT DRIVE EASF0030 BELT DRIVE V-BELT, PRIMARY AND SECONDARY SHEAVE 1 O-ring 8 Secondary sliding sheave 2 Clutch housing 9 Secondary fixed sheave 3 Clutch carrier 0 Guide pin 4 Spring A V-belt 5 Spring seat B Conical spring washer 6 Oil seal C Kickstarter one-way clutch 7 O-ring...
  • Page 147 BELT DRIVE E Primary fixed sheave F Washer G Spacer H Oil seal I Primary sliding sheave J Primary sheave weight K Slider L Plastic slider guide M Gasket ® * Shell Dolium Grease R 4 - 45...

  • Page 148: Removing The Secondary Sheave And V-Belt

    BELT DRIVE EAS00318 REMOVING THE SECONDARY SHEAVE AND V-BELT 1. Remove: • footboard Refer to “REMOVING THE FRONT COWL- ING AND LEG SHIELD” in chapter 3. 2. Remove: • V-belt case cover Refer to “KICKSTARTER”. 3. Remove: • O-ring 1 •...

  • Page 149: Removing The Primary Sheave

    BELT DRIVE 5. Remove: • secondary sheave 1 • V-belt 2 NOTE: Pull the secondary sliding sheave out as shown, remove the V-belt along with the sec- ondary sheave 1, and then remove the V-belt 2 from the primary sheave. 6.

  • Page 150: Disassembling The Secondary Sheave

    BELT DRIVE 2. Remove: • plastic slider guides 1 • slider 2 • primary sheave weights 3 • spacer 4 • oil seals EAS00319 DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: • clutch carrier nut 1 NOTE: Install the clutch spring holder 2 onto the sec- ondary sheave as shown.

  • Page 151: Checking The Clutch Housing

    BELT DRIVE EAS00290 CHECKING THE CLUTCH HOUSING 1. Check: • clutch housing Damage/wear → Replace. 2. Measure: • clutch housing inside diameter a Out of specification → Replace the clutch housing. Clutch housing inside diameter 112 mm (4.41 in) <Limit>: 112.5 mm (4.43 in) EAS00291 CHECKING THE CLUTCH SHOES The following procedure applies to all of the...

  • Page 152: Checking The V-Belt

    BELT DRIVE EAS00320 CHECKING THE V-BELT 1. Check: • V-belt 1 Cracks/damage/wear → Replace. Grease/oil → Clean the primary and sec- ondary sheave. 2. Measure: • V-belt width a Out of specification → Replace. V-belt width 18.2 mm (0.72 in) <Limit>: 17.2 mm (0.68 in) EAS00321 CHECKING THE PRIMARY SHEAVE...

  • Page 153: Assembling The Primary Sheave

    BELT DRIVE 2. Check: • torque cam groove 1 Damage/wear → Replace the secondary fixed and sliding sheaves as a set. 3. Check: • guide pin 2 Damage/wear → Replace the secondary fixed and sliding sheaves as a set. 4. Check: •...
  • Page 154 BELT DRIVE 4. Install: • primary sheave weights 1 • spacer 2 • plastic slider guides 3 • slider 4 5. Install: • primary sliding sheave 1 NOTE: When installing the primary sliding sheave, hold the slider to prevent the primary sheave weights from falling out of the primary sliding sheave.

  • Page 155: Assembling The Secondary Sheave

    BELT DRIVE EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: • secondary fixed sheave’s inner surface 1 • secondary sliding sheave’s inner surface 2 • oil seals • bearings (with the recommended lubricant) Recommended lubricant ® Shell Dolium Grease R CAUTION: Do not get any grease on the surfaces of the sheaves.
  • Page 156 BELT DRIVE 4. Install: • guide pin 1 5. Lubricate: • guide pin groove 1 • O-rings 2 (with the recommended lubricant) Recommended lubricant ® Shell Dolium Grease R NOTE: ® Apply 1 cc of Shell Dolium Grease R to the guide pin groove.

  • Page 157: Installing The Belt Drive

    BELT DRIVE 7. Install: • spring • clutch carrier 1 NOTE: • Attach the clutch spring holder 2 onto the secondary sheave as shown. Then, com- press the spring, and tighten the clutch car- rier nut 3. • Install the clutch carrier nut with the beveled side of the nut facing the clutch carrier.
  • Page 158 BELT DRIVE 2. Install: • clutch carrier nut 55 Nm (5.5 m · kg, 40 ft · lb) NOTE: While holding the clutch carrier with the rotor holding tool 1, tighten the clutch carrier nut with the socket wrench 2. Rotor holding tool 90890-01235 Socket wrench...

  • Page 159: Starter Clutch

    STARTER CLUTCH EAS00341 STARTER CLUTCH 1 Idle gear plate 2 Idle gear 3 Idle gear shaft 4 Starter clutch assembly 5 Starter wheel gear holder 6 Starter wheel gear 7 Bearing 4 - 57...

  • Page 160: Removing The Starter Clutch

    STARTER CLUTCH EAS00344 REMOVING THE STARTER CLUTCH 1. Remove: • footboard Refer to “REMOVING THE FRONT COWL- ING AND LEG SHIELD” in chapter 3. 2. Remove: • V-belt case cover Refer to “KICKSTARTER”. • primary sliding sheave Refer to “BELT DRIVE”. 3.

  • Page 161: Installing The Starter Clutch

    STARTER CLUTCH 3. Check: È É • starter clutch operation M MMM M MMM M MMM M MMM M MMM a. Install the starter wheel gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter wheel gear clock- wise È, the starter clutch and the starter wheel gear should engage, otherwise the starter clutch is faulty and must be...
  • Page 162 STARTER CLUTCH 3. Install: • starter wheel gear holder 1 • starter wheel gear holder bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Install the starter wheel gear holder in the direction shown so that the section a of the holder contacts the left crankcase.

  • Page 163: A.c. Magneto

    A.C. MAGNETO A.C. MAGNETO 1 Stator coil assembly 2 Pickup coil 3 Pickup coil bracket 4 A.C. magneto rotor 4 - 61...

  • Page 164: Removing The A.c. Magneto

    A.C. MAGNETO EAS00346 REMOVING THE A.C. MAGNETO 1. Remove: • air filter case Refer to “AIR FILTER CASE” in chapter 5. 2. Remove: • engine cooling fan cover • engine cooling fan Refer to “CYLINDER HEAD”. 3. Remove: • A.C. magneto rotor nut 1 •...

  • Page 165: Installing The A.c. Magneto

    A.C. MAGNETO EAS00354 INSTALLING THE A.C. MAGNETO For installation, reverse the removal proce- dure. 1. Install: • stator coil assembly 1 • stator coil assembly bolts 11 Nm (1.1 m · kg, 8.0 ft · lb) • pickup coil • pickup coil bracket 2 •...

  • Page 166: Oil Pump

    OIL PUMP EASF0035 OIL PUMP 1 Oil pump cover 8 Engine oil strainer 2 Oil seal 9 Spring 3 O-ring 0 O-ring 4 Gasket A Engine oil drain plug 5 Dowel pin 6 Oil pump assembly 7 Gasket 4 - 64...

  • Page 167: Removing The Oil Pump

    OIL PUMP REMOVING THE OIL PUMP 1. Drain: • engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: • footboard Refer to “REMOVING THE FRONT COWL- ING AND LEG SHIELD” in chapter 3. 3.

  • Page 168: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: • oil pump drive gear • oil pump driven gear 1 • oil pump housing 2 • oil pump housing cover 3 Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: •...

  • Page 169: Checking The Oil Strainer

    OIL PUMP EAS00368 CHECKING THE OIL STRAINER 1. Check: • oil strainer 1 Damage → Replace. Contaminants → Clean with solvent. EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (oil pump driven gear) (with the recommended lubricant) Recommended lubricant Engine oil...
  • Page 170 OIL PUMP CAUTION: After tightening the bolts, make sure the oil pump turns smoothly. 2. Install: • gasket • O-ring • oil pump cover • oil pump cover bolts 10 Nm (1.0 m · kg, 7.2 ft · lb) 4 - 68...

  • Page 171: Transmission

    TRANSMISSION EASF0041 TRANSMISSION 1 Drive axle 8 Oil seal 2 Oil seal 9 Transmission case cover 3 Conical spring washer 0 Gasket 4 Drive axle gear A Primary drive gear 5 Main axle 6 Conical spring washer 7 Dowel pin 4 - 69...
  • Page 172 TRANSMISSION EASF0042 REMOVING THE TRANSMISSION NOTE: Prior to remove the transmission, remove the muffler, rear wheel and secondary sheave. 1. Drain: • transmission oil (completely from the transmission case) Refer to “CHANGING THE TRANSMIS- SION OIL” in chapter 3. 2. Remove: •...

  • Page 173: Checking The Transmission

    TRANSMISSION 6. Remove: • drive axle 1 (with circlip) EAS00425 CHECKING THE TRANSMISSION 1. Check: • drive axle • main axle • primary drive gear • drive axle gear Damage/wear → Replace. 2. Check: • bearings Rough movement → Replace. 3.
  • Page 174 TRANSMISSION 3. Install: • primary drive gear bearing • retainer bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Install: • primary drive gear • circlip • oil seal • dowel pins • gasket • transmission case cover (with primary drive gear, bearings) •...

  • Page 175: Crankshaft

    CRANKSHAFT EASF0037 CRANKSHAFT 1 Crankcase (right) 0 Collar 2 Crankshaft assembly A Engine bracket 3 Timing chain B Spacer 4 Timing chain guide (intake side) C Centerstand shaft 5 Dowel pin D Centerstand spring 6 Crankcase (left) E Centerstand 7 Oil seal 8 Engine drain bolt 9 Rubber damper 4 - 73...

  • Page 176: Disassembling The Crankcase

    CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: • engine assembly Refer to “REMOVING THE ENGINE”. 2. Remove: • cylinder head • cylinder • piston Refer to “CYLINDER HEAD” and “CYLIN- DER AND PISTON”. 3. Remove: • V-belt case cover Refer to “KICKSTARTER”. 4.

  • Page 177: Removing The Crankshaft Assembly

    CRANKSHAFT 12.Remove: • timing chain guide (intake side) 1 13.Remove: • crankcase bolts NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 14.Remove: •...

  • Page 178: Checking The Timing Chain And Timing Chain Guide

    CRANKSHAFT EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1. Check: • timing chain Damage/stiffness → Replace the timing chain and camshaft sprocket as a set. 2. Check: • timing chain guide (intake side) Damage/wear → Replace. EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1.

  • Page 179: Checking The Crankcase

    CRANKSHAFT 4. Check: • crankshaft drive sprocket 1 Damage/wear → Replace the crankshaft. • bearings 2 Cracks/damage/wear → Replace the crank- shaft. • oil pump drive gear 3 Damage/wear → Replace the crankshaft. 5. Check: • crankshaft journal Scratches/wear → Replace the crankshaft. •...

  • Page 180: Installing The Crankshaft

    EAS00416 ASSEMBLING THE CRANKCASE 1. Apply: • sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery. 2. Install: • dowel pins 1 3.
  • Page 181 CRANKSHAFT 6. Check: • crankshaft operation Rough movement → Repair. 7. Lubricate: • centerstand shaft (with the recommended lubricant) Recommended lubricant Lithium-soap-based grease 8. Install: • centerstand spring • centerstand • centerstand shaft • washer • circlip 9. Install: • spacers •...
  • Page 182 CRANKSHAFT 12.Install: • upper engine mounting bolts 1 • nuts 2 NOTE: Push the engine bracket in the direction of the arrow shown and install the upper engine mounting bolts. 13.Tighten: • nuts 2 16 Nm (1.6 m · kg, 11 ft · lb) 4 - 80...

  • Page 183: Carb

    CARB CHAPTER 5 CARBURETOR CARBURETOR....................5-1 REMOVING THE CARBURETOR............. 5-2 DISASSEMBLING THE CARBURETOR........... 5-3 CHECKING THE CARBURETOR ............. 5-4 ASSEMBLING THE CARBURETOR............5-7 MEASURING AND ADJUSTING THE FUEL LEVEL ........5-8 INSTALLING THE CARBURETOR ............5-9 CHECKING THE FUEL COCK OPERATION..........5-9 FUEL TANK....................5-11 REMOVING THE FUEL TANK ..............5-11 INSTALLING THE FUEL TANK...............5-12 AIR FILTER CASE ..................
  • Page 184 CARB...

  • Page 185: Carburetor

    CARB CARBURETOR EASF0480 CARBURETOR CARBURETOR 1 Cylinder head breather hose 8 Coasting enricher set F Float 9 Pilot screw set G Float pivot pin holder 2 Vacuum chamber cover H Gasket 0 Needle valve I Float chamber 3 Piston valve spring A Needle jet J Fuel drain screw 4 Jet needle set...

  • Page 186: Removing The Carburetor

    CARB CARBURETOR EASF0481 REMOVING THE CARBURETOR WARNING Gasoline is highly flammable. Avoid spilling fuel on the hot engine. 1. Remove: • fuel tank Refer to “FUEL TANK”. 2. Remove: • air filter case Refer to “AIR FILTER CASE”. 3. Loosen: •...
  • Page 187 CARB CARBURETOR 9. Disconnect: • starter plunger assembly 1 (from the starter cable) EASF0483 DISASSEMBLING THE CARBURETOR NOTE: The following parts can be cleaned and inspected without disassembly. • Throttle stop screw • Pilot screw • Coasting enricher 1. Remove: •...

  • Page 188: Checking The Carburetor

    CARB CARBURETOR 4. Remove: • float pin screw 1 • float pivot pin 2 • float 3 • needle valve 4 5. Remove: • main jet 1 • needle jet holder 2 • cap 3 • needle jet 4 • pilot jet 5 6.
  • Page 189 CARB CARBURETOR 2. Check: • fuel passages Obstruction → Clean. M MMM M MMM M MMM M MMM M MMM a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air.
  • Page 190 CARB CARBURETOR 9. Check: • jet needle holder 1 • jet needle spring 2 • jet needle 3 • needle jet holder 4 • needle jet 5 • main jet 6 • pilot jet 7 • pilot screw 8 Bends/damage/wear → Replace. Obstruction →...

  • Page 191: Assembling The Carburetor

    CARB CARBURETOR EAS00487 ASSEMBLING THE CARBURETOR For assembly, reverse the disassembly proce- dure. CAUTION: • Before assembling the carburetor, wash all of the parts in a petroleum-based sol- vent. • Always use a new gasket and O-ring. 1. Install: • pilot screw Pilot screw setting 2-3/8 turns out 2.

  • Page 192: Measuring And Adjusting The Fuel Level

    CARB CARBURETOR EAS00498 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust. Fuel level (above the float cham- ber mating surface) 7.0 ~ 9.0 mm (0.28 ~ 0.35 in) M MMM M MMM M MMM M MMM M MMM...

  • Page 193: Installing The Carburetor

    CARB CARBURETOR EAS00492 INSTALLING THE CARBURETOR For installation, reverse the removal proce- dure. 1. Install: • carburetor assembly NOTE: When installing the carburetor assembly, align the slot a in the carburetor assembly with the projection b on the intake manifold. 2.
  • Page 194 CARB CARBURETOR 2. Check: • fuel cock operation M MMM M MMM M MMM M MMM M MMM a. Suck on the end of the vacuum hose 1. Fuel flows. Fuel cock is OK. Replace the fuel Fuel does not flow. cock.

  • Page 195: Fuel Tank

    CARB FUEL TANK EASF0006 FUEL TANK REMOVING THE FUEL TANK 1. Remove: • side cover (left and right) Refer to “REMOVING THE SEAT AND SIDE COVERS” in chapter 3. 2. Remove: • battery Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. 3.

  • Page 196: Installing The Fuel Tank

    CARB FUEL TANK INSTALLING THE FUEL TANK For installation, reverse the removal proce- dure. 1. Install: • fuel tank 7 Nm (0.7 m · kg, 5.1 ft · lb) • grab bar 7 Nm (0.7 m · kg, 5.1 ft · lb) 2.

  • Page 197: Air Filter Case

    CARB AIR FILTER CASE EASF0009 AIR FILTER CASE REMOVING THE AIR FILTER CASE 1. Remove: • footboard Refer to “REMOVING THE FRONT COWL- ING AND LEG SHIELD” in chapter 3. 2. Remove: • V-belt case air duct Refer to “KICKSTARTER” in chapter 4. 3.

  • Page 199: Chas

    CHAS CHAPTER 6 CHASSIS FRONT WHEEL AND BRAKE DISC............... 6-1 REMOVING THE FRONT WHEEL............6-2 CHECKING THE FRONT WHEEL ............6-3 CHECKING THE BRAKE DISC..............6-5 CHECKING THE SPEEDOMETER GEAR UNIT ........6-6 INSTALLING THE FRONT WHEEL ............6-7 REAR WHEEL AND BRAKE ................6-9 REMOVING THE REAR WHEEL AND REAR BRAKE ......
  • Page 200 CHAS REAR SHOCK ABSORBER ASSEMBLY ............6-49 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....6-50 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....6-51 CHECKING THE CRANKCASE (LEFT)..........6-51 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....6-51...

  • Page 201: Front Wheel And Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC EASF0044 CHASSIS FRONT WHEEL AND BRAKE DISC 1 Front wheel axle 8 Front wheel 2 Brake disc 3 Spacer 4 Oil seal 5 Bearing 6 Spacer 7 Speedometer gear unit 6 - 1...

  • Page 202: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00519 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • speedometer cable 1 •...

  • Page 203: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00526 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent wheel axle. Wheel axle bending limit 0.25 mm (0.0098 in) 2.
  • Page 204 CHAS FRONT WHEEL AND BRAKE DISC 5. Check: • spacers Damage/wear → Replace. WARNING • After mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim. Failure to do so could lead to an accident with possible injury to the rider or dam- age to the motorcycle.

  • Page 205: Checking The Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC CAUTION: Do not contact the wheel bearing inner race 4 or balls 5. Contact should be made only with the outer race 6. NOTE: Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal. L LLL L LLL L LLL...

  • Page 206: Checking The Speedometer Gear Unit

    CHAS FRONT WHEEL AND BRAKE DISC 3. Measure: • brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Brake disc thickness limit (mini- mum) 3.0 mm (0.12 in) 4. Adjust: • brake disc deflection M MMM M MMM M MMM...

  • Page 207: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: • wheel axle • wheel bearings • oil seal lips • speedometer gear unit Recommended lubricant Lithium-soap-based grease 2. Install: • speedometer gear unit 1 NOTE: • Make sure that the speedometer gear unit and the wheel hub are installed with the pro- jection a of the wheel hub inserted in a slot b of the speedometer gear unit.
  • Page 208 CHAS FRONT WHEEL AND BRAKE DISC 5. Tighten: • wheel axle nut 40 Nm (4.0 m · kg, 29 ft · lb) WARNING Make sure the brake hose is routed prop- erly. CAUTION: Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly.

  • Page 209: Rear Wheel And Brake

    CHAS REAR WHEEL AND BRAKE EASF0049 REAR WHEEL AND BRAKE 1 Axle nut 0 Brake camshaft lever 2 Rear wheel A Adjusting nut 3 Brake shoe spring (brake camshaft side) B Pin 4 Brake shoe spring (pivot side) C Rear brake cable spring 5 Brake shoe D Rear brake cable 6 Brake camshaft...

  • Page 210: Removing The Rear Wheel And Rear Brake

    CHAS REAR WHEEL AND BRAKE EAS00563 REMOVING THE REAR WHEEL AND REAR BRAKE 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 211: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE 6. Remove: • brake shoes 1 • brake shoe spring (brake camshaft side) 2 • brake shoe spring (pivot side) 3 7. Remove: • brake camshaft 1 • washer 2 EAS00566 CHECKING THE REAR WHEEL 1.

  • Page 212: Checking The Brake

    CHAS REAR WHEEL AND BRAKE EAS00569 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: • brake shoe lining Glazed areas → Repair. Sand the glazed areas with course sandpa- per. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth.

  • Page 213: Installing The Rear Wheel And Rear Brake

    CHAS REAR WHEEL AND BRAKE EAS00573 INSTALLING THE REAR WHEEL AND REAR BRAKE 1. Lubricate: • brake camshaft Recommended lubricant Lithium-soap-based grease 2. Install: • washer • brake camshaft 1 WARNING After installing the brake camshaft, remove any excess grease. NOTE: Install the brake camshaft 1 with the punch mark a facing away from the motorcycle.
  • Page 214 CHAS REAR WHEEL AND BRAKE 5. Install: • brake camshaft lever 1 • brake camshaft lever bolt 2 • pin 3 • rear brake cable 4 • adjusting nut 5 NOTE: • Align the punch mark on the brake camshaft with the mark on the brake camshaft lever positioned as shown a.

  • Page 215: Front Brake

    CHAS FRONT BRAKE FRONT BRAKE EASF0052 FRONT BRAKE CALIPER 1 Brake hose holder 7 Brake caliper piston 2 Brake caliper upper bolt 8 Brake caliper seal 3 Brake pad holding bolt 9 Brake pad shim 4 Bleed screw kit 0 Brake pad 5 Brake caliper lower bolt A Brake pad spring 6 Brake caliper...

  • Page 216: Replacing The Front Brake Pads

    CHAS FRONT BRAKE EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 217 CHAS FRONT BRAKE 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.031 in) 4. Install: • brake pad shim (onto the brake pad) •...

  • Page 218: Disassembling The Front Brake Caliper

    CHAS FRONT BRAKE 6. Install: • brake pad holding bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) • pin • brake caliper • brake caliper upper bolt 43 Nm (4.3 m · kg, 31 ft · lb) •...

  • Page 219: Checking The Front Brake Caliper

    CHAS FRONT BRAKE 2. Remove: • pin 1 • brake pad holding bolt 2 • brake pads 3 (along with the brake pad shim) • brake pad spring 4 3. Remove: • brake caliper piston 1 • brake caliper piston seals 2 M MMM M MMM M MMM...
  • Page 220 CHAS FRONT BRAKE 1. Check: • brake caliper piston 1 Rust/scratches/wear → Replace the brake caliper piston. • brake caliper cylinder 2 Scratches/wear → Replace the brake cali- per assembly. • brake caliper body 3 Cracks/damage → Replace the brake cali- per assembly.
  • Page 221 CHAS FRONT BRAKE 2. Install: • brake caliper 1 (temporarily) • copper washers 2 • brake hose 3 • union bolt 4 26 Nm (2.6 m · kg, 19 ft · lb) WARNING Proper brake hose routing is essential to insure safe motorcycle operation.
  • Page 222 CHAS FRONT BRAKE WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • Page 223: Front Brake Master Cylinder

    CHAS FRONT BRAKE EASF0050 FRONT BRAKE MASTER CYLINDER 1 Brake master cylinder 9 Front brake light switch 2 Brake lever 0 Copper washer 3 Brake master cylinder kit A Union bolt 4 Brake master cylinder reservoir cap B Brake hose 5 Brake master cylinder reservoir diaphragm holder 6 Brake master cylinder reservoir diaphragm...

  • Page 224: Disassembling The Front Brake Master Cylinder

    CHAS FRONT BRAKE EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • front cowling Refer to “REMOVING THE FRONT COWL- ING AND LEG SHIELD” in chapter 3. 2.
  • Page 225 CHAS FRONT BRAKE 9. Remove: • left handlebar switch 1 NOTE: Remove the left handlebar switch from the meter assembly cover. 10.Remove: • union bolt 1 • copper washers 2 • brake hose 3 • brake lever 4 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

  • Page 226: Checking The Front Brake Master Cylinder

    CHAS FRONT BRAKE 14.Remove: • brake master cylinder reservoir cap 1 • brake master cylinder reservoir diaphragm holder 2 • brake master cylinder reservoir diaphragm 3 • plate 4 15.Remove: • brake hose holder 1 • brake hose 2 EAS00590 CHECKING THE FRONT BRAKE MASTER CYLINDER 1.

  • Page 227: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT BRAKE 4. Check: • brake hose 1 Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER For assembly and installation, reverse the dis- assembly and removal procedure. WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 228 CHAS FRONT BRAKE 3. Install: • brake master cylinder 1 • brake master cylinder bracket • brake master cylinder bracket upper bolt 11 Nm (1.1 m · kg, 8.0 ft · lb) • brake master cylinder bracket lower bolt (temporarily) NOTE: •...
  • Page 229 CHAS FRONT BRAKE WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
  • Page 230 CHAS FRONT BRAKE 9. Install: • meter assembly cover 1 • left handlebar switch bracket NOTE: When installing the meter assembly cover, make sure that the gap between the brake master cylinder bracket 2 and the meter assembly cover is uniform. If the gap is not uniform, loosen the bolt in the hole a in the meter assembly cover and adjust the position of the brake master cylinder bracket.

  • Page 231: Front Fork

    CHAS FRONT FORK EASF0054 FRONT FORK 1 Front fork cap bolt 7 Dust seal 2 O-ring 8 Oil seal clip 3 Fork spring 9 Oil seal 4 Damper rod 0 Outer tube 5 Rebound spring A Front fender 6 Inner tube 6 - 31...

  • Page 232: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00651 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

  • Page 233: Disassembling The Front Fork Legs

    CHAS FRONT FORK EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: • fork spring 2. Drain: • fork oil NOTE: Stroke the inner tube 1 several times while draining the fork oil. 3.

  • Page 234: Checking The Front Fork Legs

    CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

  • Page 235: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 236 CHAS FRONT FORK 3. Tighten: • damper rod assembly bolt 1 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: While holding the damper rod assembly with the hexagon socket wrench (10 mm) 2 and T-handle 3, tighten the damper rod assembly bolt.
  • Page 237 CHAS FRONT FORK 5. Install: • oil seal clip 1 NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. 6. Install: • dust seal 1 (with the fork seal driver weight 2) Fork seal driver weight 90890-01184 7.

  • Page 238: Installing The Front Fork Legs

    CHAS FRONT FORK EAS00663 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. For installation, reverse the removal proce- dure. 1. Install: • front fork leg 1 • lower bracket lower pinch bolt 2 •...

  • Page 239: Handlebar

    CHAS HANDLEBAR EASF0055 HANDLEBAR 1 Rearview mirror 7 Handlebar grip 2 Throttle grip 8 Rear brake lever 3 Throttle cable spring 9 Rear brake cable 4 Right handlebar switch 0 Starter cable 5 Handlebar A Throttle cable 6 Left handlebar switch 6 - 39...

  • Page 240: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • leg shield Refer to “REMOVING THE FRONT COWL- ING AND LEG SHIELD”...
  • Page 241 CHAS HANDLEBAR 8. Disconnect: • rear brake light switch connectors 1 9. Remove: • rear brake cable 2 • rear brake lever assembly 3 10.Remove: • starter lever screw 1 • washer • starter lever 2 • starter cable 3 •...

  • Page 242: Checking The Handlebar

    CHAS HANDLEBAR EAS00668 CHECKING THE HANDLEBAR 1. Check: • handlebar 1 Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handle- bar as this may dangerously weaken it. EAS00673 INSTALLING THE HANDLEBAR For installation, reverse the removal proce- dure.
  • Page 243 CHAS HANDLEBAR 5. Install: • spring washer 1 • washer • starter cable • starter lever • washer • screw 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Install the spring washer in the direction shown. 6. Install: •...
  • Page 244 CHAS HANDLEBAR 8. Install: • throttle cable 1 • throttle grip 2 • throttle cable housing (front side) 3 NOTE: • Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar. •...

  • Page 245: Steering Head

    CHAS STEERING HEAD EASF0057 STEERING HEAD 1 Upper ring nut 7 Lower bearing 2 Lower ring nut 8 Lower bracket 3 Ball race cover 9 Brake hose holder bracket 4 Bearing inner race 0 Speedometer cable guide 5 Upper bearing 6 Bearing outer race 6 - 45...

  • Page 246: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • leg shield Refer to “REMOVING THE FRONT COWL- ING AND LEG SHIELD”...

  • Page 247: Checking The Steering Head

    CHAS STEERING HEAD EAS00681 CHECKING THE STEERING HEAD 1. Clean: • bearings • bearing races Recommended cleaning solvent Kerosene 2. Check: • bearings 1 • bearing races 2 Damage/pitting → Replace. 3. Replace: • bearings • bearing races M MMM M MMM M MMM M MMM...

  • Page 248: Installing The Steering Head

    CHAS STEERING HEAD EAS00683 INSTALLING THE STEERING HEAD For installation, reverse the removal proce- dure. 1. Lubricate: • upper bearing • lower bearing • bearing races Recommended lubricant Lithium-soap-based grease 2. Install: • upper bearing 1 • lower bearing 2 NOTE: Install the upper and lower bearings with the projection a on each bearing facing up.
  • Page 249 CHAS REAR SHOCK ABSORBER ASSEMBLY EASF0058 REAR SHOCK ABSORBER ASSEMBLY 1 Rear shock absorber 6 - 49...
  • Page 250 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 251 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Oil leaks → Replace the rear shock absorber assembly. •...

  • Page 253: Elec

    – ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................ 7-1 CHECKING SWITCH CONTINUITY..............7-3 CHECKING THE SWITCHES................7-5 CHECKING THE BULBS AND BULB SOCKETS .......... 7-7 TYPES OF BULBS ..................7-7 CHECKING THE CONDITION OF THE BULBS ........7-8 CHECKING THE CONDITION OF THE BULB SOCKETS .......7-9 IGNITION SYSTEM ..................
  • Page 254 – ELEC...

  • Page 255: Electrical System

    – ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Fuse 8 Turn signal relay 2 Starter relay 3 Fuel sender 4 C.D.I. unit 5 Rectifier/regulator 6 Ignition coil 7 Horn 7 - 1...
  • Page 256 – ELEC ELECTRICAL COMPONENTS 1 Main switch 2 Fuse 3 Positive battery lead 4 Battery 5 Negative battery lead 6 Wire harness 7 - 2...

  • Page 257: Checking Switch Continuity

    – ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY “∞” “0” Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. “Ω×1” CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.
  • Page 258 – ELEC CHECKING SWITCH CONTINUITY 7 - 4...

  • Page 259: Checking The Switches

    – ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 260 – ELEC CHECKING THE SWITCHES 1 Rear brake light switch 2 Horn switch 3 Dimmer switch 4 Turn signal switch 5 Front brake light switch 6 Light switch 7 Start switch 8 Main switch 9 Fuse 7 - 6...

  • Page 261: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
  • Page 262 – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 263: Checking The Condition Of The Bulbs

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE:...

  • Page 264: Ignition System

    – ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM 1 Main switch 2 Fuse 3 Battery 7 A.C. magneto 8 C.D.I. unit 9 Ignition coil 0 Spark plug 7 - 10...

  • Page 265: Troubleshooting

    – ELEC IGNITION SYSTEM EAS00736 EAS00738 TROUBLESHOOTING 1. Fuse The ignition system fails to operate (no • Check the fuse for continuity. spark or intermittent spark). Refer to “CHECKING THE FUSE” in chap- ter 3. Check: • Is the fuse OK? 1.
  • Page 266 – ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance • Disconnect the spark plug cap from the • Remove the spark plug cap from the spark spark plug. plug lead. • Connect the ignition checker 1 as shown. •...
  • Page 267 – ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Pickup coil resistance • Disconnect the ignition coil connector from • Disconnect the A.C. magneto coupler from the ignition coil terminal. the wire harness. • Connect the pocket tester (Ω × 1) to the •...
  • Page 268 – ELEC IGNITION SYSTEM EAS00754 9. Wiring • Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the ignition system’s wiring properly connected and without defects? Replace the C.D.I. Properly connect or unit. repair ignition system’s wiring. 7 - 14...

  • Page 269: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 1 Main switch 2 Fuse 3 Battery 4 Starter motor 5 Starter relay C Start switch D Front brake light switch E Rear brake light switch 7 - 15...

  • Page 270: Starting Circuit Cut-Off System Operation

    – ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON” (switch is closed), the starter motor can only operate if at least one of the following conditions is met: • The front brake lever is pulled to the handle- bar (the front brake light switch is closed).

  • Page 271: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00738 TROUBLESHOOTING 1. Fuse The starter motor fails to turn. • Check the fuse for continuity. Refer to “CHECKING THE FUSE” in chap- Check: ter 3. 1. fuse • Is the fuse OK? 2. battery 3.
  • Page 272 – ELEC ELECTRIC STARTING SYSTEM EAS00758 EAS00761 3. Starter motor 4. Starter relay • Connect the positive battery terminal 1 • Disconnect the starter relay coupler from and starter motor lead 2 with a jumper the starter relay. lead 3. •...
  • Page 273 – ELEC ELECTRIC STARTING SYSTEM EAS00749 EAS00766 5. Main switch 9. Wiring • Check the main switch for continuity. • Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. • Is the main switch OK? •...

  • Page 274: Starter Motor

    – ELEC STARTER MOTOR EASF0767 STARTER MOTOR 1 Starter motor rear cover 2 Starter motor yoke 3 Armature 4 Bush set 5 Starter motor front cover assembly BRUSH LENGTH LIMIT: 3.5 mm (0.14 in) COMMUTATOR WEAR LIMIT: 21 mm (0.83 in) MICA UNDER CUT: 1.5 mm (0.06 in) ARMATURE COIL RESISTANCE:...

  • Page 275: Removing The Starter Motor

    – ELEC STARTER MOTOR REMOVING THE STARTER MOTOR 1. Remove: • footboard Refer to “REMOVING THE FRONT COWL- ING AND LEG SHIELD” in chapter 3. 2. Remove: • battery Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. 3. Remove: •...

  • Page 276: Checking The Starter Motor

    – ELEC STARTER MOTOR 4. Remove: • armature 1 EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 21 mm (0.83 in) 3.
  • Page 277 – ELEC STARTER MOTOR 4. Measure: • armature assembly resistances (commuta- tor and insulation) Out of specification → Replace the starter motor. M MMM M MMM M MMM M MMM M MMM a. Measure the armature assembly resis- tances with the pocket tester. Pocket tester 90890-03112 Armature coil...

  • Page 278: Assembling The Starter Motor

    – ELEC STARTER MOTOR 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 5.52 ~ 8.28 N (563 ~ 844 gf, 19.87 ~ 29.80 oz) 7. Check: • gear teeth Damage/wear →...

  • Page 279: Installing The Starter Motor

    – ELEC STARTER MOTOR INSTALLING THE STARTER MOTOR For installation, reverse the removal proce- dure. 1. Install: • starter motor 1 • negative battery lead 2 • starter motor bolts 7 Nm (0.7 m · kg, 5.1 ft · lb) 7 - 25...

  • Page 280: Charging System

    – ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 2 Fuse 3 Battery 6 Rectifier/regulator 7 A.C. magneto 7 - 26...

  • Page 281: Troubleshooting

    – ELEC CHARGING SYSTEM EAS00774 EAS00738 TROUBLESHOOTING 1. Fuse The battery is not being charged. • Check the fuse for continuity. Refer to “CHECKING THE FUSE” in chap- Check: ter 3. 1. fuse • Is the fuse OK? 2. battery 3.
  • Page 282 – ELEC CHARGING SYSTEM EAS00775 EAS00776 3. Charging voltage 4. Charging coil resistance • Connect the engine tachometer to the • Disconnect the A.C. magneto coupler from spark plug lead. the wire harness. • Connect the pocket tester (Ω × 1) to the •...

  • Page 283: Lighting System

    – ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 1 Main switch 2 Fuse 3 Battery 6 Rectifier/regulator 7 A.C. magneto B Light switch J Dimmer switch O Tail/brake light R Headlight U Meter light V High beam indicator light 7 - 29...

  • Page 284: Troubleshooting

    – ELEC LIGHTING SYSTEM EAS00781 EAS00738 TROUBLESHOOTING 1. Fuse Any of the following fail to light: head- • Check the fuse for continuity. light, high beam indicator light, taillight Refer to “CHECKING THE FUSE” in chap- or meter light. ter 3. •...
  • Page 285 – ELEC LIGHTING SYSTEM EAS00783 EAS00776 4. Light switch 6. Lighting coil resistance • Check the light switch for continuity. • Disconnect the A.C. magneto coupler from Refer to “CHECKING THE SWITCHES”. the wire harness. • Connect the pocket tester (Ω × 1) to the •...

  • Page 286: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EAS00788 High beam indicator light CHECKING THE LIGHTING SYSTEM Positive tester probe → yellow 4 1. The headlight and the high beam indicator Negative tester probe → black 5 light fail to come on. 1. Headlight bulb and socket •...
  • Page 287 – ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light bulb and socket 1. Tail/brake light bulb and socket • Check the meter light bulb and socket for •...

  • Page 288: Signaling System

    – ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 1 Main switch 2 Fuse 3 Battery D Front brake light switch E Rear brake light switch F Turn signal relay G Horn I Horn switch K Turn signal switch M Rear turn signal light (left) N Rear turn signal light (right) O Tail/brake light P Front turn signal light (left)

  • Page 289: Troubleshooting

    – ELEC SIGNALING SYSTEM EAS00794 EAS00738 TROUBLESHOOTING 1. Fuse • Any of the following fail to light: turn • Check the fuse for continuity. signal light, brake light or an indicator Refer to “CHECKING THE FUSE” in chap- light. ter 3. •...

  • Page 290: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EAS00795 EAS00796 CHECKING THE SIGNALING SYSTEM 4. Wiring 1. The horn fails to sound. • Check the entire signal system’s wiring. 1. Horn switch Refer to “CIRCUIT DIAGRAM”. • Is the signaling system’s wiring properly • Check the horn switch for continuity. connected and without defects? Refer to “CHECKING THE SWITCHES”.
  • Page 291 – ELEC SIGNALING SYSTEM EAS00798 3. Horn 2. The tail/brake light fails to come on. • Disconnect the pink connector at the horn 1. Tail/brake light bulb and socket terminal. • Connect a jumper lead 1 to the horn ter- •...
  • Page 292 – ELEC SIGNALING SYSTEM EAS00799 3. Voltage 3. The turn signal light, turn signal indicator light or both fail to blink. • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) 1. Turn signal indicator light bulb and socket as shown.
  • Page 293 – ELEC SIGNALING SYSTEM 3. Voltage 4. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness turn signal relay coupler (wire harness side) as shown.
  • Page 294 – ELEC SIGNALING SYSTEM 5. Voltage • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Connect the pocket tester (DC 20 V) to the • Measure the voltage (DC 12 V) of the turn signal light coupler (wire harness chocolate 1 or dark green 2 at the turn side) as shown.
  • Page 295 – ELEC SIGNALING SYSTEM EAS00804 2. Voltage 4. The fuel level gauge fails to operate. • Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter light coupler (wire harness side) as • Remove the fuel sender from the fuel tank. shown.
  • Page 296 – ELEC SIGNALING SYSTEM 3. Fuel level gauge • Set the main switch to “ON”. • Move the float up 1 or down 2. • Check that the fuel level gauge needle moves to “F” or “E”. NOTE: Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes.

  • Page 297: Trbl Shtg

    TRBL SHTG CHAPTER 8 TROUBLESHOOTING TROUBLESHOOTING..................8-1 ELECTRICAL SYSTEM................8-1 COMPRESSION SYSTEM................ 8-2 INTAKE AND EXHAUST SYSTEM ............8-3...
  • Page 298 TRBL SHTG...

  • Page 299: Troubleshooting

    TRBL TROUBLESHOOTING SHTG EASF0062 TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL SYSTEM 8 - 1...

  • Page 300: Compression System

    TRBL TROUBLESHOOTING SHTG COMPRESSION SYSTEM WEAR/SCRATCH/DAMAGE WEAR/STICK/BROKEN INSUFFICIENT TIGHTENING TORQUE WEAR/SCRATCH DAMAGE WEAR/CARBON DEPOSITS DAMAGE INSUFFICIENT TIGHTENING TORQUE 8 - 2...

  • Page 301: Intake And Exhaust System

    TRBL TROUBLESHOOTING SHTG INTAKE AND EXHAUST SYSTEM 8 - 3...
  • Page 304 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 305 AL115 WIRING DIAGRAM 1 Main switch 2 Fuse 3 Battery 4 Starter motor W/R W/L 5 Starter relay (BLACK) 6 Rectifier/regulator Br R 7 A.C. magneto 8 C.D.I. unit 9 Ignition coil 0 Spark plug A Right handlebar switch B Light switch C Start switch D Front brake light switch E Rear brake light switch...

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